Solid surface composite

ABSTRACT

A light weight solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member and a reinforcing member disposed on at least one preselected area of the second layer, and a surface coat. The surface coat includes a densified resin and methyl methacrylate, and is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and the reinforcing member.

CROSS-REFERENCE TO RELATED APPLICATIONS

The invention taught in this patent application is closely related to the following co-pending U.S. patent applications, “Process for Making Solid Surface Composites” and “Surface Coat Formula for Solid Surface Composites”. These co-pending applications numbered xx/xxx,xxx and xx/xxx,xxx were filed on July, 2005 and July, 2005. Further, the teachings of the above mentioned applications are incorporated herein by reference hereto.

FIELD OF THE INVENTION

The present invention relates, in general, to a composite material, and more specifically, the present invention relates to a new formulation for a lightweight composite for use as counter tops, shower surrounds, bath tubs, sinks and various other preselected products for use in such areas as kitchens and bathrooms.

BACKGROUND OF THE INVENTION

There are many materials that are used to form counter tops that are used in such areas as the kitchens and bathrooms. Different materials have been used for years to form tops that are both attractive and can withstand the use that the tops encounter through the constant usage that such counter top must endure. This is particularly true with the kitchen counter top.

Several problems exist with present counter tops. One problem is that corners, back splashes and side splashes are not normally seamless. Further sinks are not integrated into the counter top. Thus, there tends to be unsightly corners and back and side splashes that have to glued onto the counter top providing a point where moisture can compromise the integrity of the top.

SUMMARY OF THE INVENTION

The present invention provides a light weight solid surface composite. The solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member and a reinforcing member disposed on at least one preselected area of the second layer, and a surface coat. The surface coat includes a densified resin and methyl methacrylate, and is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and the reinforcing member.

OBJECTS OF THE INVENTION

It is, therefore, one of the primary objects of the present invention to provide a lightweight solid surface composite that can be used for kitchen and bathroom counter tops, shower surrounds, bathtubs, sinks and various other similar applications.

Another object of the present invention is to provide a lightweight solid surface composite in which back and side splashes are seamless.

Still another object of the present invention is to provide a lightweight solid surface composite in which back and side splashes are integrated into the counter top surface.

Yet another object of the present invention is to provide a lightweight solid surface composite in which the corners are seamless.

Another object of the present invention is to provide a lightweight solid surface composite in which the surface coat is formed by atomized casting rather than being poured.

It is still another object of the present invention to provide a lightweight solid surface composite in which the product contains particle board and corrugated cardboard to increase tensile strength.

Yet, it is still another object of the present invention to provide a lightweight solid surface composite in which the product weighs only about 20% of the weight of presently used counter tops.

These and various other objects and advantages of this invention will become apparent after a full reading of the following detailed description, particularly, when read in conjunction with the attached drawings as described below and the appended claims.

BRIEF DESCRIPTION OF THE PRESENTLY PREFERRED AND ALTERNATE EMBODIMENTS OF THE INVENTION

The present invention provides a unique solid surface composite that can be used for kitchen and bathroom counter tops, shower surrounds, bath tubs, sinks and a wide variety of other preselected personal and commercial products.

The present invention provides a light weight solid surface composite. The solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member. A reinforcing member is disposed on at least one preselected area of the second layer, and a surface coat is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and to the reinforcing member. The surface coat includes a densified resin and methyl methacrylate. It is presently preferred that such densified resin is a polyester resin. It is further preferred that such surface coat is an atomized casting that is sprayed rather than being a poured product.

The reinforcing member is disposed in the corners of the solid composite. Such reinforcing member according to a presently preferred embodiment of the invention includes a putty of cotton flock and a low profile tooling resin. Such low profile tooling resin is selected from a polyester resin. Such reinforcing member provides additional strength for the corners and radius of the surface coat.

There is a first layer of fiber reinforcement and a low profile tooling resin that is disposed into said composite. It is preferred that such fiber is fiberglass and that such fiberglass is chopped fiberglass. It is further preferred that this reinforcement is hand laminated onto the cotton flock. The resin coat is disposed on and adhered to into the core member. It is presently preferred that such core member is particle board and corrugated cardboard. Such core member provides significantly increased tensile strength to the composite. The second layer of fiber reinforced, low profile tooling resin is also laminated onto the core. It is presently preferred that such second layer is hand laminated.

It is also preferred that such surface coat also includes an air release and wetting agent, a mold release agent and fumed silica.

Such a light weight solid surface composite when it is used to form a counter top provides a counter top that is seamless at the corners and which also has back splashes and side splashes that are seamless. It is preferred that such back splashes and side splashes be integrated into the counter top as a single unit.

The present invention according to an alternate embodiment also provides a molded in sink that is integrated into the counter top surface.

Such composite made according to the present invention provides a counter top that is significantly lighter than the counter tops that are commercially available. The difference in weight is dramatic. The counter top of the present invention is only between about 18% and about 30% of the weight of presently available tops. These light weight counter tops generally are only about 20% of the weight of the present counter tops. Thus, the difference in weight makes the tops of the present invention far easier and less expensive to install. Further, since the counter top is an integrated top the top does not permit moisture to compromise the integrity of the counter top during repeated use over time.

While both the presently preferred and a number of alternative embodiments of the present invention have been described in detail above it should be understood that various other adaptations and modifications of the present invention can be envisioned by those persons who are skilled in the relevant art without departing from either the spirit of the invention or the scope of the appended claims. 

1. A light weight solid surface composite, said solid surface composite comprising: (a) a core member; (b) a resin coat having a first side disposed on and adhered to a first side of said core member; (c) a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said resin coat; (d) a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said core member; (e) a reinforcing member disposed on at least one preselected area of said second layer; and (f) a surface coat including a densified resin and methyl methacrylate, said surface coat disposed on and adhered to said second layer of fiber reinforced low profile tooling resin and said reinforcing member disposed on said at least one preselected area of said second layer.
 2. The light weight solid surface composite, according to claim 1, wherein said reinforcing member includes cotton flock and low profile tooling resin.
 3. The light weight solid surface composite, according to claim 1, wherein said surface coat further includes an air release and wetting agent, a mold release agent, and fumed silica.
 4. The light weight solid surface composite, according to claim 1, wherein said fiber reinforcing member includes fiberglass.
 5. The light weight solid surface composite, according to claim 3, wherein said fiberglass is chopped fiberglass.
 6. The light weight solid surface composite, according to claim 1, wherein said core member includes at least one of particle board and corrugated cardboard.
 7. The light weight solid surface composite, according to claim 6, wherein said core member significantly increases tensile strength.
 8. The light weight solid surface composite, according to claim 1, wherein said composite is a counter top.
 9. The light weight solid surface composite, according to claim 8, wherein said counter top is seamless adjacent at least one corner thereof.
 10. The light weight solid surface composite, according to claim 8, wherein back splashes and side splashes on said counter top are seamless.
 11. The light weight solid surface composite, according to claim 8, wherein back splashes and side splashes on said counter top are integrated into said counter top surface as a single piece unit.
 12. The light weight solid surface composite, according to claim 8, wherein said light weight solid surface counter top is significantly lighter than counter tops that are commercially available.
 13. The light weight solid surface composite, according to claim 12, wherein said light weight solid surface counter top weighs between about 18 and 30 per cent of the weight of commercially available counter tops.
 14. The light weight solid surface composite, according to claim 13, wherein said light weight solid surface counter top weighs about 20 per cent of the weight of commercially available counter tops.
 15. The light weight solid surface composite, according to claim 8, wherein said light weight solid surface counter top further includes a molded in sink that is integrated into a surface of said counter top.
 16. The light weight solid surface composite, according to claim 1, wherein said at least one preselected area includes at least one corner of said light weight solid surface composite.
 17. The light weight solid surface composite, according to claim 16, wherein said at least one preselected area includes a plurality of corners of said light weight solid surface composite.
 18. The light weight solid surface composite, according to claim 1, wherein said densified resin is a polyester.
 19. The light weight solid surface composite, according to claim 1, wherein said surface coat is an atomized spray.
 20. The light weight solid surface composite, according to claim 1, wherein said surface coat has a high gloss finish. 